All Materials & Processes Articles, Interviews, Stories & Videos

When it comes to 3D printing versus injection molding, the best production method for your parts will become clear when you can answer these questions regarding your desired quantity, quality and cost.

From Nature.com:
Ultimately, Goh, a PhD candidate at the National University of Singapore, hopes that the method will help her to find blood vessels that are leaking owing to inflammation, perhaps helping to detect malaria or predict strokes. Crucial to her technique are the virus-sized particles that give the solution its colour. Just a few tens of nanometres across, they are among a growing array of 'nanolights' that researchers are tailoring to specific types of fluorescence: the ability to absorb light at one wavelength and re-emit it at another.
Many naturally occurring compounds can do this, from jellyfish proteins to some rare-earth compounds. But nanolights tend to be much more stable, versatile and easier to prepare — which makes them attractive for users in both industry and academia.
The best-established examples are quantum dots: tiny flecks of semiconductor that are prized for their beautiful, crisp colours. Now, however, other types of nanolight are on the rise. Some have a rare ability to absorb lots of low-energy photons and combine the energy into a handful of high-energy photons — a trick that opens up opportunities such as producing multiple colours at once. Others are made from polymers or small organic molecules. These are less toxic than quantum dots and often outshine them — much to the amazement of chemists, who are used to carbon-based compounds simply degrading in the presence of ultraviolet light... ( full article )

Viknesh Vijayenthiran for Discovery News: New materials will also play a significant role in the further evolution of the car, according to BMW. This has already started with the increasing use of carbon fiber and other composites instead of conventional steel.
Looking further forward, technologies such as rapid manufacturing and 4-D printing (3D-printed materials that change depending on conditions) will open up new possibilities.
One of the more interesting aspects of the concept is a technology called Alive Geometry which consists of 4D-printed components that can change their shape and interact with the driver. Full Article:

The project Mobile Robotic Fabrication System for Filament Structures, developed by ITECH graduate Maria Yablonina, demonstrates a new production process for filament structures. It proposes multiple semi-autonomous wall climbing robots to distribute fiber filament, using any horizontal or vertical surface, or even existing architecture, to support the new structures. Compared to larger scale industrial robots that are limited by position and reach, these robots are enabled with movement systems and a collection of sensors that allow them to travel and interact accurately along typical ground, walls, roofs, and ceilings. One can imagine a fabrication process where an operator arrives to the scene with a suitcase housing all the necessary robots and materials to create a large structure. These agile mobile robotic systems move robotic fabrication processes beyond the constraints of the production hall, exposing vast urban and interior environments as potential fabrication sites.

From The Economist's Technology Quarterly:
This is what some scientists describe as a “golden age” for materials. New, high-performing substances such as exotic alloys and superstrong composites are emerging; “smart” materials can remember their shape, repair themselves or assemble themselves into components. Little structures that change the way something responds to light or sound can be used to turn a material into a “metamaterial” with very different properties...
...When it comes to making chemical bonds, one element, carbon, is in a league of its own; a more or less infinite number of distinct molecules can be made from it. Chemists call these carbon-based molecules organic, and have devoted a whole branch of their subject—inorganic chemistry—to ignoring them. Mr Ceder’s Materials Project sits in that inorganic domain. It has simulated some 60,000 materials, and five years from now should reach 100,000. This will provide what the people working on the project call the “materials genome”: a list of the basic properties—conductivity, hardness, elasticity, ability to absorb other chemicals and so on—of all the compounds anyone might think of. “In ten years someone doing materials design will have all these numbers available to them, and information about how materials will interact,” says Mr Ceder. “Before, none of this really existed. It was all trial and error... ( full article )

Fonons Canyon 3D Deep-Engraving System cost is less expensive, deep-engraves at almost 2X the processing speed, requires no consumables and is 100% maintenance-free. There is no workplace or environmental hazards with a superior quality of workmanship when compared to vertical milling machines.

Kitchen maker Nobilia has rolled out IoT and automation systems in its German factories to enable real-time tracking of furniture as it progresses through the manufacturing process.
The company, which has distribution in Australia, is using Beckhoff automation technology that is powered by Intel processors.
A barcode that is attached to furniture is encoded with details including processing steps, components required to be added to complete it, and logistics information such as where the finished product is to be delivered.
“Each processing machine scans the barcode and retrieves the associated machining data from a central database. Data connecting the whole factory together makes it possible to produce 2700 kitchens daily,” Intel said in a blog post.
“Through real-time tracking enabled by Intel IoT technologies, Nobilia knows exactly where each part is in the production process at any time.
“If one of the manufacturing lines shuts down, parts are automatically rerouted to another line.”

From MIT News:
Concrete is the world’s most widely used construction material, so abundant that its production is one of the leading sources of greenhouse gas emissions. Yet answers to some fundamental questions about the microscopic structure and behavior of this ubiquitous material have remained elusive.
Concrete forms through the solidification of a mixture of water, gravel, sand, and cement powder. Is the resulting glue material (known as cement hydrate, CSH) a continuous solid, like metal or stone, or is it an aggregate of small particles...
... Roland Pellenq, a senior research scientist in MIT’s department of civil and environmental engineering, director of the MIT-CNRS lab 2 hosted by the MIT Energy Initiative, and a co-author of the new paper, says the work builds on previous research he conducted with others at the Concrete Sustainability Hub (CSHub) through a collaboration between MIT and the CNRS. “We did the first atomic-scale model” of the structure of concrete, he says, but questions still remained about the larger, mesoscale structure, on scales of a few hundred nanometers. The new work addresses some of those remaining uncertainties, he says. ( full article )

By Kira for 3ders.org: The first month of 2016 is now behind us, and the year is shaping up to be particularly interesting in terms of 3D printing trends. In the advanced materials sector specifically, emerging technologies firmLux Research has predicted that the top three ‘undercover’ advanced materials trends of 2016 include improved 3D printing software and formats, Carbon nanotube products, and IoT devices embedded with sensing materials. Cont'd...

The Internet of Things (IoT) is enabling manufacturers to be more efficient, productive and profitable in the face of increased competition worldwide. We look at five reasons why manufacturers are betting big on these new technologies.

Scott J Grunewald for 3DPrint.com: A team of engineers from the University of Bristol — comprising Thomas M. Llewellyn-Jones, Bruce W. Drinkwater and Richard S. Trask — have developed a new hybrid type of 3D printing that can both assemble and print with composite materials using a combination of desktop 3D printer technology, light-curable resins and ultrasonic waves. This new process can allow super strong and lightweight composites like the variety used to produce tennis rackets, golf clubs, professional bicycles or even airplane parts to be used with additive manufacturing technology. Needless to say these new material options will offer entire new industries the ability to incorporate 3D printing into their manufacturing workflow. And the best part is that for the most part the process was made using existing 3D printing technology.
Composite materials are made by combining micro-structures of glass or carbon fibers with a plastic material. The carefully arranged fibers lock together and give the new material its strength and durability, while the plastic ensures that the resulting material will be lightweight. Currently, composite materials are manufactured as thin sheets that are then layered and cut into the desired shape and thickness. The problem with using this as a 3D printing material is the small fibers in the composite materials. In order to produce the desired strength the fibers need to be aligned in a very precise structure, which is currently not possible to reproduce using a 3D printer. Cont'd.. .

From Hanchen Huang of Northeastern University:
MesoGlue is our revolutionary joining solution that lets you attach items together with a metal bond, at room temperature. This is like welding or soldering, but without the heat! The patented process gives you the strength and thermal/electrical conductance of a metal bond, with the ease of attachment of glue or tape. Surfaces are merely pressed together to form a very strong connection.
Our MesoGlue technology can be applied to nearly any flat surface. The surface can be rigid or flexible, and roll-to-roll processing is possible. We currently offer coating of two joining surfaces at our state of the art processing facility. Items of up to approximately 1 cubic foot can be accommodated.
MesoGlue Silver:
A pure silver bond offering the highest electrical and thermal conductivity. Formation of the bond requires moderate pressure.
MesoGlue Eutectic:
A bond made of primarily copper with other metals added to help the process. Formation of the bond requires only fingertip pressure.
(MesoGlue Homepage)

My research involves developing techniques to 3D print electric motors and electronics. This goes beyond the usual 3D printed structures - structures dont do anything. To do things, we need motors and electronics to control those motors.

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